Battery won’t charge beyond 72%

[mjdonat]

Hi can anyone inform me why my Platinum 2022 Lightning won’t charge beyond 65-75%? It charges up to somewhere in that range then just arbitrarily jumps to 100% and says it’s full. You unplug the truck and it drops back down to say 68%. This all started happening after a series of recalls were performed on the vehicle at the dealer.

I’ve also check and rechecked all settings in the app and on the truck, it’s programmed to charge to 90%. Has anyone else experienced this? Thanks for any advice or tips.

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[TaxmanHog]

This has been a symptom of trucks which had a recent HVB module swap, have any of your modules been changed out?

 

[mjdonat]

I’m not 100% sure but I think they have been. The truck went into “limp mode” with the amber wrench displayed on dash, wouldn’t go faster than 3-5 mph. I had it towed in, they fixed that and a bunch of recalls. I asked them what that did or what caused the “limp mode” and amber wrench. The explanation involved something about modules not communicating with one another requiring a large software update. But modules was definitely mentioned because I’ve never heard of that before. So what’s the fix now? Take it back to dealer?

 

[invertedspear]

Yes, back to the dealer. In a personal electronic device this means one of your battery cells is likely dead. In a more complex battery pack like this, it could mean a dead module, or just a bad BMS that’s not getting the right data from modules. Nothing you’re going to be able to do to solve this in your driveway.

 

[mjdonat]

Ugh ok I was afraid of that. I’ll call the dealer on Monday. Thanks guys

 

[skyak]

Mine did this a couple weeks ago, wouldn't charge past 65% or so and wrench on dash. I took it to dealer and they replaced a battery module and did a bunch of software configuring / updates.
One thing to watch out for is that they will most likely not flush your coolant properly, so plan on adding coolant to the system after you get it back from the dealer. Installing a new battery module requires them to disconnect and reconnect the module to the coolant loop.

 

[Bandit216]

Hi can anyone inform me why my Platinum 2022 Lightning won’t charge beyond 65-75%? It charges up to somewhere in that range then just arbitrarily jumps to 100% and says it’s full. You unplug the truck and it drops back down to say 68%. This all started happening after a series of recalls were performed on the vehicle at the dealer.

I’ve also check and rechecked all settings in the app and on the truck, it’s programmed to charge to 90%. Has anyone else experienced this? Thanks for any advice or tips.

What TaxManHog said. This is the exact behavior my 22 Lariat exhibited after a battery module swapout. I took mine back to the dealer and they called back the same day and said Ford told them it would take 21 days for the truck to relearn the correct battery capacity. I would run it down to below 10% battery remaining then do a 100% charge. Each time it did that I would gain a few percent before it would do the jump to 100%. I did built an app that let's me display the essential battery data on the Sync Screen so I could watch the max kWh available increase with each 10-100% charge as well.

Well, it did eventually relearn its full battery capacity. It did however take a lot longer than 21 days, though. It was closer to 21 weeks. I got the truck back the first week of April but it wasn't until a few weeks ago that 100% was equal to 131 kWh available - and the battery health has jumped to 99%.

I may have been responsible for the extra time though as I did some tinkering with FDRS to force the battery to relearn its capacity. Everything is great now. There were some power limitations, but those went away as the "relearned" capacity got above 100kWh or so.

Here is a photo I took of the blessed full capacity event.

 

[GoodSam]

built an app that let's me display the essential battery data on the Sync Screen

Wow, how is an app like that created? CarScanner? Would like to know more if you could write up a new thread, perhaps? Or point me to a thread that covers this?

 

[Heliian]

did however take a lot longer than 21 days, though. It was closer to 21 weeks.

Sounds like the dealer didn't have all the necessary tooling and info to perform a module swap but did anyway.

Of the many module swaps talked about here, you're the only one to mention this extended balancing, "relearning" as they called it.

 

[skyak]

What TaxManHog said. This is the exact behavior my 22 Lariat exhibited after a battery module swapout. I took mine back to the dealer and they called back the same day and said Ford told them it would take 21 days for the truck to relearn the correct battery capacity. I would run it down to below 10% battery remaining then do a 100% charge. Each time it did that I would gain a few percent before it would do the jump to 100%. I did built an app that let's me display the essential battery data on the Sync Screen so I could watch the max kWh available increase with each 10-100% charge as well.

Well, it did eventually relearn its full battery capacity. It did however take a lot longer than 21 days, though. It was closer to 21 weeks. I got the truck back the first week of April but it wasn't until a few weeks ago that 100% was equal to 131 kWh available - and the battery health has jumped to 99%.

I may have been responsible for the extra time though as I did some tinkering with FDRS to force the battery to relearn its capacity. Everything is great now. There were some power limitations, but those went away as the "relearned" capacity got above 100kWh or so.

Here is a photo I took of the blessed full capacity event.

Wow that is a crazy saga. Glad mine did not have this issue. When I picked mine up I noticed that it was at the same state of charge as when I left it. I wonder if the issue occurs when charging is initiated without all modules present or properly connected. Or maybe it's got to do with the difference between charge state of module removed and module installed.

 

[TaxmanHog]

Sounds like the dealer didn't have all the necessary tooling and info to perform a module swap but did anyway.

Of the many module swaps talked about here, you're the only one to mention this extended balancing, "relearning" as they called it.

I'm only speculating, but with the rash of module failures and backlog of work to be completed, the engineers may have relaxed the requirements for getting the replacement module aligned with the rest of the pack.

Some tech's might not have gotten it balanced as close as recommended and this resulted in an extended retraining timeframe.

 

[Bandit216]

Wow, how is an app like that created? CarScanner? Would like to know more if you could write up a new thread, perhaps? Or point me to a thread that covers this?

Yes. I use Car Scanner and run it from a stand alone Car Play device that I keep plugged into the USB port. That way it autostarts everytime I start the car and I can keep my phone in my pocket. I'll see if I can download a copy of what I built.

 

[Bandit216]

Wow, how is an app like that created? CarScanner? Would like to know more if you could write up a new thread, perhaps? Or point me to a thread that covers this?

I was able to save a copy of the Car Scanner Pro file (.cbz) I use on my Lightning. It is, however, formatted for Sync via my stand-alone CarPlay device. I was able to reformat it to fit the Android phone if you want to run Car Scanner Pro from your Android phone. I can send you copies of both if you want to share your email via private message. I really don't have time to build a thread describing the way to build Car Scanner apps. There is already quite a bit of info out there that describes the process.

I would recommend you just save a couple copies of the .cbz files I send. You can then open Car Scanner Pro, go to 'Settings', Select 'Backup', then at the bottom of the Backup screen Select 'Import from File' and select the location where you saved a copy of the .cbz file I use. Once you've done that you go back to the car Scanner Pro and select 'Demo' mode in the lower right corner. You can then play with the file and reformat to fit your display device and move or add new fields to learn how to build Car Scanner pages. In demo mode you won't be connected to your truck so you can play with Car Scanner to your heart's content without affecting the truck. Be aware, in demo mode Car Scanner will be filling the display fields with a bunch of random and rapidly changing data so the data will have no relation to the kind of data you could expect to see on the Lightning - things like negative number for battery capacity, triple digit temperatures, etc. So, in Demo mode, ignore the data, just learn how to change or move the data fields.

When you have the Data page the way you want it you can exit Demo mode, start your car, go to settings and select the OBD adapter you are using (2nd field), exit back to the main screen, select "Connect' at the bottom, after it connects to the OBD adapter, go to the upper left and select 'Dashboard'. It will open to the number one data screen. You can scroll between data screens by swiping right or left. Have fun.

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